大连金城伟业化工泵有限公司 Dalian Jinchen Weiye Chemical Pump Co. Ltd. | 铸造工序作业指导书 Operation Instruction for Casting Working Procedure | 共4页 Total pages 4 | ||||||||||
1. 制芯 Core making 1.1准备工作及注意事项 Preparations and notices 1.1.1准备好制芯用具：脱模剂等。 Ready for core making tools: mold-release agent etc. Ready for automatic-hardening resin sand, the quality of it should be in compliance with the steel casting technology, no veins, scab defects etc. in the process of use. 1.1.33837Cc检查模具是否完好：是否有磨损异常，联结处松动等。 Check if the moulds are in good conditions, whether there are some worn parts, loose connections, etc. 1.1.4检查各电器箱的电线有无松动，烧焦现象，如有要马上请修好后才能送电。 Check all the electric wire, make sure they are not loosened, burned, or they must be repaired before electricity connected. 1.1.5检查加料斗是否备足树脂褐变度砂，如不足，要加足。 Check if the loading hopper is full with resin sand, if no, load it. 2. 造型、修型 Mould shaping and mending 2.1 准备工作及注意事项 Preparations and notices 2.1.1 准备好造型用具：脱模剂等。 Ready for the core making tools: mold-release agent etc. 2.1.1 准备好树脂砂，其质量要符合钢型工艺的质量要求，使用过程中铸件无脉纹、夹砂等缺陷。 Ready for the resin sand, the quality of it should be in compliance with the steel casting technology，no veins, scab defects in the process of use. 弓箭制作 If the model needs to draw out with crane, slowly dropping the crane to draw the model out so as to divide the mould and model smoothly, lest the resin sand broken. 2.2 修型准备工作及注意事项 Preparations and notices for mould mending 2.2.1准备好修型用的工具及原材料：粘接剂、修型工具、钢锯片、废砂轮片等。 Get the tools and materials ready: bond agent, repairing tools, metal saw blades, waste grinding wheel pieces, etc. 第1页 Page 1 Check if the mould is shot full before the core loaded, check if it is mended well, if not, mend it. Clear out the resin sand adhered on the well parts of the mould lest any lumps adhering on the mould. 2.2.3修补时要小心，不允许有树脂砂掉在铸型内，如果有要及时吹干净。 Be careful while mending, resin sand is not allowed dropping in the mould, or it should be blow out completely. 2.2.4型芯的涂刷要刷够3层，等层之间进行干燥后逐一刷涂为好，涂料应该是一次的涂料层为0.3mm左右。 The core should be painted 3 layers, the latter layer should be painted after the previous one dried. The thickness of each layer is around 0.3mm. 3. 下芯 Core loading 3.1准备工作及注意事项 Preparations and notices 3.1.1准备好修好检查合格的砂芯。 Get the good qualified core ready 3.1.2把砂芯上的定位凸台对准铸型中的定位凹坑，砂芯装下后要用手摇晃一下看能否晃动。 Put the retaining lugs into the dented parts, make some shakes to convince that it is no loosen. 3.1.3现场的芯子在没有完全硬化的情况下不能进行刷涂。 Painting should be done after the core completely hardened. 3.1.4现场固化剂的配比要使用量杯准确配比。 The proportion of the hardening agent should be measured precisely with measuring cup. 3.1.5现场的员工必须熟知粘砂部位，建议粘砂部位宝珠砂的厚度达到15mm以上；易粘砂部位建议刷涂进行3次。 The workers must well know the sand stuck parts, suggest the thickness of the pearl sand on the stuck parts be above 15mm and the sand easy stuck parts painted 3 times. 3.1.6装完砂芯要用风管把散砂吹出来。 Blow out the residue sands after the core loading. 4. 合箱 Mould assembling 4.1 操作要求 Operation requirements 4.1.1用风管将铸型的散砂吹干净，防止粘砂。 Blast all the residue sand from the casting mould with blast pipe to prevent sand sticking. 第2页 Page 2 | ||||||||||||
4.1.2合箱过程要平稳，吊车下降不能过快，防止合箱产生崩砂。 The mould assembling process should be steady, do not let the crane falling too fast lest the sand collapsed while assembling. 4.2控制要点 Key points of controlling 4.2.1合箱前要检查铸型是否完好，固化是否符合要求，不完好处要进行修补，同时清理干净粘砂和披锋，吹干净铸型。 Check if the casting moulds are in good condition before mould assembling begins, check if they are well solidified according to the requirements. Mend those parts not meet the requirements. Clear up the stuck sands and the fins, blast the casting mould clean 4.2.2合箱前要认真检查，不允许型腔内有松散砂存在，同时直浇道内不允许有披锋和积砂存在。 Make a careful check before mould assembling begins, residue sands should not be existed in mould cavity, downsprue pass is not allowed to exist fins and accumulated sand. Pouring 准备工作及注意事项 Preparations and notices 5.1.1钢包在进行浇注前一定要进行烘烤，时间为1-1.5小时，烘烤温度控制在900℃-1000℃。 Surely heat the steel ladle before pouring, heating time is around 1-1.5 hours, heating temperature is controlled between 900℃-1000℃. 5.1.2浇注前注意挡渣，确保覆盖剂层能随铁水位下降而下降，无渣块随铁水流入铸型中。 Slag should be kept off before pouring, guarantee the covering agent layer falling with the molten steel’s falling level, no slag should be flowing into the mould cavity with molten steel. 5.1.3调整浇包包嘴与浇口杯的距离，浇注包口要对准浇口杯，高度以距离浇口100-200MM为宜，保持铁流连续注入，保持浇口杯充满，不得断流。 Adjust the distance between the casting ladle mouth and the sprue cup, the mouth should be aimed at the cup, the distance is around 100-200mm, keep the molten steel pouring continuously, keep the sprue cup full and no cutoff of the molten steel. 5.1.4板胡制作浇注完毕后剩余的铁水应妥善处理，不得随便乱倒，包内铁水残渣应清除干净。 Properly handle the spare molten steel after pouring, do not litter it casually, the residues in the ladle should be cleared up. 6. 开箱出铸件、清砂 Separate mould assembly, take out casting, clean up sand 6.1.1浇注后约25-30分钟后方可进行移动车灯透镜，可以提前5分钟打开箱扣。 The castings can be moved only around 25-30 minutes after pouring, the assembling buckles can be opened 5 minutes ahead. 6.1.2为保证铁型的覆砂温度，要求开一箱，清理一箱，覆砂一箱。 Each time the mould assembling opens, clear work should be done and then follows sand coating in order to keep the mould’s coating sand temperature. 第3页 Page 3 6.1.3铸件开箱必须在浇注后24小时打箱落砂。 The opening of the mould assembling should be done 24 hours later after pouring. Strike the assembling boxes to drop the sand. 6.1.4开箱结束后要将全部的热砂箱造好型，待第二天进行浇注，以便于砂箱能快速循环使用。 After the opening, all the warm moulding flasks should be placed on working condition for next day’s pouring and for rapid recycling use. 7.铸件清理及外观检验 Foundry goods cleaning and outface inspection 7.1.1理化检验完后待铸件完全冷却后开始清理，用砂轮机打磨去除铸件表面的披锋和多肉。 After physical and chemical analysis and after completely cooling of the foundry goods, cleaning work should be done, remove the fins and surplus parts with grounding wheel. 7.1.2将打磨好的铸件放入抛丸机中抛丸清理，抛丸后铸件表面应无粘砂、锈迹等。 Put the grounded foundry goods into shot-blasting machine for clearing, the finished castings should be no stuck sand and rust, etc. on the surfaces. 7.1.3要求100﹪进行外观检验，铸造表面的氧化皮、飞边要去除干净，铸件不允许有裂纹、杂质、夹渣、孔隙和其他外观缺陷，零件在加工表面不能出现砂孔、气孔等影响使用的缺陷，铸件错模最大不能 超过0.76mm。 The surface must be 100% inspected, the oxide coating and fins should be cleared up, cracks, wastes, mingled slag, holes and other kinds of surface defects on the castings are not allowed to exist, sand holes and air holes, etc. are not allowed to exist on the processing surface, the mould assembling error of the casting should be less than 0.76mm. 7.1.4做好铸件的防锈工作，必要时涂抹防锈油。 The foundry goods should rust prove, coat it with rust preventing oil if necessary. | ||||||||||||
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